College of Engineering

Applied Thermodynamics
Module Code: M3H324915
 
 
 

 DrM Achuthan
 
 Department of

Mechanical and Industrial Engineering

Programme : CAME Level 3

Reciprocating Air Compressor

Air compressors
Compressors are work absorbing devices which are used for increasing
pressure of fluid at the expense of work done on fluid.

The compressors used for compressing air are called air compressors.
Compressors are invariably used for all applications requiring high pressure
air.
Application of Air Compressors

Some of popular applications of compressor are, for driving pneumatic

tools and air operated equipments, spray painting, compressed air engine,
supercharging in internal combustion engines, material handling (for
transfer of material), surface cleaning, refrigeration and air conditioning,
chemical industry etc.

Compressors are supplied with low pressure air (or any fluid) at inlet which
comes out as high pressure air (or any fluid) at outlet. Work required for
increasing pressure of air is available from the prime mover driving
the compressor.

Generally, electric motor, internal combustion engine or steam engine,

turbine etc. are used as prime movers. Compressors are similar to fans and
blowers but differ in terms of pressure ratios.

Fan is said to have pressure ratio up to 1.1 and blowers have pressure
ratio between 1.1 and 4 while compressors have pressure ratios more
than 4
Reciprocating Air compressors
• Reciprocating air compressors are positive displacement type of air compressors.

Block diagram

Principle of Operation
• The principle of operation is same but according to stages, the delivery pressure
is different in each compressor.
• A reciprocating air compressor consist of a piston which is enclosed within a
cylinder and equipped with suction and discharge valve
• The compression of air is done by first drawing a volume of air into the cylinder
through suction valve during suction stroke of piston and then compressed and
discharged through delivery valve during delivery stroke
P-V diagram for Reciprocating Compressor:

Referring to the diagram, the theoretical air compressor P-V diagram can be understood.
 
4-1: The air compressor draws in air from the atmosphere. The atmospheric pressure is P1. The
initial volume when the piston is at top is zero (Assuming there is no bumping clearance). Thus
as the piston moves from top to bottom, a volume of air V1 is drawn into the compressor. The
temperature of air is T1.
1-2: As the piston moves up, the air is compressed polytropically ( ). The pressure of air
increases from P1 to P2. The volume decreases from V1 to V2. The temperature increases from T1
to T2.
2-3: The compressed air at the pressure P2, volume V2 and temperature T2 is delivered out of the
compressor to the air receiver.
Thermodynamic analysis on compressor:
 Compression of air in compressor may be carried out following number of thermodynamic
Processes such as isothermal compression, polytropic compression or adiabatic compression.

Figure shows the thermodynamic cycle involved in compression. Theoretical cycle is shown
neglecting clearance volume but in actual cycle clearance volume cannot be negligible.
Clearance volume is necessary in order to prevent collision of piston with cylinder head,
accommodating valve mechanism etc.
Compression process is shown by process 1– 2, 1–2’, 1–2” following adiabatic, polytropic and
isothermal processes respectively.
 On p-V diagram process 4–1 shows the suction process followed by compression during 1–2 and
discharge through compressor is shown by process 2–3. Air enters compressor at pressure p1 and
is compressed up to p2.
 Compression work requirement can be estimated from the area below the each compression
process.
 Area on p–V diagram shows that work requirement shall be minimum with isothermal process 1–2’.
 Work requirement is maximum with process 1–2 i.e. adiabatic process.
 As a designer one shall be interested in a compressor having minimum compression
work requirement. Therefore, ideally compression should occur isothermally for
minimum work input. In practice it is not possible to have isothermal compression
because constancy of temperature during compression cannot be realized.
 
Generally, compressors run at substantially high speed while isothermal compression
requires compressor to run at very slow speed so that heat evolved during
compression is dissipated out and temperature remains constant.
 
Actually due to high speed running of compressor the compression process may be
assumed to be near adiabatic or polytropic process following law of compression as
with value of ‘n’ varying between 1.25 and 1.35 for air.
 
Compression process following three processes is also shown on T-s diagram. It is
thus obvious that actual compression process should be compared with isothermal
compression process. A mathematical parameter called isothermal efficiency is defined
for quantifying the degree of deviation of actual compression process from ideal
compression process. Isothermal efficiency is defined by the ratio of isothermal work
and actual indicated work in reciprocating compressor.
Work by the compressor is area in PV diagram:
Without clearance volume

𝑃2 𝑉 2 − 𝑃1 𝑉 1
 
[
𝑊 𝑐= 𝑃 2 𝑉 2 + ( 𝑛 −1 ) − 𝑃1 𝑉 1
]
Considering clearance volume:

With clearance volume the cycle is represented on Fig. The work done for compression
of air polytropically can be given by the area enclosed in cycle 1–2 –3–4.

Clearance volume in compressors varies from 1.5% to 35% depending upon type of
compressor.
 In case of compressor having isothermal compression process ie. n=1
 
and

In case of compressor having adiabatic compression process ie. n =

 

 
 
For single acting compressor running with N rpm, power input required,
assuming clearance volume.

For double acting compressor running with N rpm, power input required, assuming
clearance volume.

  

 𝐌 𝐞𝐚𝐧 𝐞𝐟𝐟𝐞𝐜𝐭𝐢𝐯𝐞 𝐩𝐫𝐞𝐬𝐬𝐮𝐫𝐞 𝑃 = 𝑊 𝑐 = 𝑊𝑐

( 𝑚)
𝑉 𝑠 ( 𝑉 1 −𝑉 3 )
Volumetric efficiency:

Volumetric efficiency of compressor is the measure of the deviation from volume

handling capacity of compressor. Mathematically, the volumetric efficiency is given
by the ratio of actual volume of air sucked and swept volume of cylinder. Ideally the
volume of air sucked should be equal to the swept volume of cylinder, but it is not so
in actual case. Practically the volumetric efficiency lies between 60 and 90%.
  Volume free air delivery
𝑽𝒐𝒍𝒖𝒎𝒆𝒕𝒓𝒊𝒄 𝐞𝐟𝐟𝐢𝐜𝐢𝐞𝐧𝐜𝐲 𝛈 𝐯𝐨𝐥 =
Swept volume
  𝑉𝑎 (𝑉 1 −𝑉 4)
𝑽𝒐𝒍𝒖𝒎𝒆𝒕𝒓𝒊𝒄 𝐞𝐟𝐟𝐢𝐜𝐢𝐞𝐧𝐜𝐲 ( 𝛈𝐯𝐨𝐥 ) = =
𝑉𝑠 (𝑉 1 −𝑉 3 )
  𝑃2 ( 1𝒏 )
𝑽𝒐𝒍𝒖𝒎𝒆𝒕𝒓𝒊𝒄 𝐞𝐟𝐟𝐢𝐜𝐢𝐞𝐧𝐜𝐲 ( 𝛈𝐯𝐨𝐥 ) =1+ 𝐾 − K
𝑃1 ( )
  𝑉𝑐
𝑲 =𝑪𝒍𝒆𝒂𝒓𝒂𝒏𝒄𝒆 𝑹 𝐚𝐭𝐢𝐨 = x 100
𝑉𝑠
Mass Flow

Mass
  flow rate is the rate at which mass enters the inlet during suction
The mass flow rate is simply given by
Methods of improving Isothermal efficiency of the Compressor

The following practical methods are achieve nearly isothermal compression(n

little above 1) for high speed compressor. The objective is to reduce the final
temperature T2 during compression so that actual work approaches to
isothermal.

Spray Injection:
Water Jacketing :
Inter cooling:
External fins:
The isothermal efficiency of a compressor should be close to 100% which means
that actual compression should occur following a process close to isothermal
process.
For this the mechanism be derived to maintain constant temperature during
compression process.
Different arrangements which can be used are:
(i) Faster heat dissipation from inside of compressor to outside by use of fins over
cylinder. Fins facilitate quick heat transfer from air being compressed to
atmosphere so that temperature rise during compression can be minimized.
(ii) Water jacket may be provided around compressor cylinder so that heat can be
picked by cooling water circulating through water jacket. Cooling water
circulation around compressor regulates rise in temperature to great extent.
(iii) The water may also be injected at the end of compression process in order to
cool the air being compressed. This water injection near the end of compression
process requires special arrangement in compressor and also the air gets mixed
with water and needs to be separated out before being used. Water injection also
contaminates the lubricant film on inner surface of cylinder and may initiate
corrosion etc. The water injection is not popularly used.
(iv) In case of multistage compression in different compressors operating serially,
the air leaving one compressor may be cooled up to ambient state or somewhat
high temperature before being injected into subsequent compressor. This cooling
of fluid being compressed between two consecutive compressors is called
intercooling and is frequently used in case of multistage compressors.
Effect of Inter cooling
1. Isothermal compression reduces compressor work hence saving in power.
2. Volumetric efficiency is increased. volumetric efficiency is the ratio of the amount of gas entering
the compressor (suction) versus the amount of gas leaving the compressor (discharge).since due to inter -cooling the
volume of air is reduced due to reduction of temperature and hence the amount of air inlet after intercooler to next stage
has increased which will also increase the amount of air discharge. Hence volumetric efficiency will increase.
3. Reduced the volume of air delivered and also reduced the compressor size. When we compare a compressor having
inter-cooler to the one having no inter-cooler , the compressor without intercooler will be bigger in size for the same
output then the compressor with inter-cooler.
4. It reduces the air temperature. Since it is a heat exchange process and Due to less temperature suction & delivery
valves remain cleaner without being fouled with carbonized oil. High temperature operation requires frequent
maintenance.
5. It allows good lubrication of the compressor piston. For proper lubrication(cylinder & piston ring) to establish there
must be optimum temperature if temperature is high due to any reason, the lubrication will break which result in metal-
to-metal contact and increases the wear.
6. Moisture separation is easier through inter cooler drains. It is using atmospheric air to compress it and by default
atmospheric air contains moisture which is harmful in many ways so every intercooler is fitted with drain valve.
Moisture will get condensed when it come in contact with cooling media and that will be drained by drain valve fitted
in inter-cooler.
7. It also enables to deal with a greater weight of air for the same energy expended. Due to reduction in volume the
mass and the weight of air will increase for the next stage of compression.
Single stage Reciprocating Air compressors
 Single stage air compressor develop pressure upto 7 bar.
 For higher pressures multistage compressors are suitable

Double (Multi) stage Reciprocating Air compressors

MULTI STAGE PISTON COMPRESSOR

As per general gas laws, if the pressure increases temperature also increases.

For example : if the exit pressure of compressor is 5 bar in a single acting

compressor, the compressor air temperature can rise to over 200 and the motor
power needed to drive the compressor rises.

Therefore single stage compressors are not used for high pressures. Multistage
compressors are used when high pressures are required, because better
cooling between stages can effectively increase the efficiency and reduce the
input power requirements.

Single stage machines compress the air to pressure of about 6 bars and in
exceptional cases to 10 bars, two stage machines normally discharge pressure
up to 15 bars. Discharge pressures in the range of 250 bars can be obtained
with high pressure reciprocating compressor of three and four stages.
Double stage Reciprocating Air compressors
• It consist of two cylinders – low pressure cylinder and high pressure
cylinder
• Piston, crankcase, piston rod, crank, crankshaft, oil, fins etc.
• The fresh air is drawn inside the L.P. cylinder through inlet suction filter.
• This air is compressed by piston
• As the piston moves towards the end of cylinder, the air compression took
place.
• The delivery valve opens and this compressed air from L.P. cylinder is
directed to enter inside the high pressure cylinder.
• In high pressure cylinder this pressurised air is further compressed to
higher pressure.
• The high pressure air from H.P. cylinder is then delivered to receiver
through discharge valves.
• In this compressor, a pressure of air delivered is upto 13 bar.
Advantages

•Simple in design ,
•Lower initial cost,
•Easy to install,
•Higher efficiency

Disadvantages

•Number of moving parts are more

•Higher maintenance cost
•Heavy foundation is required as it has vibration problem
•Cannot run at full capacity
Working:
Following Figure shows the two stage (inline type) reciprocating air compressor.
When the prime mover connected to crank shaft rotates, crank rotates and the
piston in the first stage reciprocates. It sucks the air through the suction filter and
inlet valve. The air, compressed to a certain degree passes from the left
cylinder to right cylinder through the intermediate cooler. The compression ratio in
the first stage is determined by the degree of cooling required.

Figure. Multi stage piston air compressor with intercooler

1. A single stage, single acting reciprocating air compressor delivers 0.7 kg/min of air at 6 bar. The suction
temperature and pressure are 25°C and 1 bar. The bore diameter and stroke length of the compressor are 100 mm
and 150 mm respectively. Neglecting clearance volume and assuming index of compression to be 1.3, calculate:

(i) Power required to be supplied to drive the compressor if mechanical efficiency is 85%;
(ii) Isothermal efficiency;
(iii) Speed of the compressor.

Take R = 0.287 kJ/kgK for air.

 
P1 = 1 bar =100 kPa; P2 = 6 bar = 600 kPa
T1 = 25oC = 298 K, n = 1.3
= 0.7 kg/min = 0.01167 kg/s,
Mech. Effi. = 85%
L = 150 mm = 0.15 m
D = 100 mm = 0.1 m
 

 
2. 1 m3/min of air enters a single stage single acting reciprocating air compressor at 1 bar and
20°C. The compression occurs following polytropic process with index 1.23 upto the delivery
pressure of 12 bar. The compressor runs at the speed of 240 rpm and has L/D ratio of 1.8.
Neglecting the clearance volume, calculate:
(i) Compressor work input;
(ii) Isothermal efficiency of the compressor;
(iii)Stroke length (L) and bore diameter (D).

V1 = 1 m3/min = 0.0167 m3/s

P1 = 1 bar =100 kPa
T1 = 20oC
N = 240 rpm
L/D = 1.8
 

 
3. The suction temperature and pressure to a single stage, single acting reciprocating air
compressor are measured as 27°C and 1.1 bar respectively. The compressor delivers air at 0.91
kg/min at a pressure of 8 bar. If the bore diameter and stroke length of the compressor are 100
mm and 150 mm respectively, determine the following:
i) Brake Power required to drive the compressor assuming mechanical efficiency of 77%.
ii) Isothermal work input required and efficiency of the compressor;
iii) Overall isothermal efficiency;
iv) RPM for the compressor;
v) Volumetric efficiency.
Neglect the clearance volume and assume that compression process follows the polytropic
process: PV1.3 = C.
 
P1 = 1.1 bar =110 kPa; P2 = 8 bar = 800 kPa; T1 = 25oC = 298 K;
n = 1.3; Mech. Effi. = 77%;
= 0.91 kg/min = 0.015167 kg/s;
L = 150 mm = 0.15 m; D = 100 mm = 0.1 m
 
=
;
= = 2791.38 = ;
x100 = x100 = 77.9%;
x100 = x100 = 60%;

;
x100 = x100 = x100 = 96.49 %;
4. Air is compressed polytropically from 1 bar and 25oC to 7 bar in a reciprocating air compressor. Compression follows
the law PV1.27 = C. If the indicated power of 6.5 kW is required to drive the compressor, neglecting clearance, evaluate
the following:

(i) Mass flow rate of air in kg/s;

(ii) Compressor speed if stroke length and bore diameter for the compressor are 220 mm and 180 mm respectively;
(iii) Isothermal efficiency of compressor;
(iv) Mean Effective Pressure.
Assume R for air as 0.287 kJ/kgK respectively.

Given:
PV1.27 = C
P1 = 1 bar =100 kPa
T1 = 25oC = 298 K
P2 = 7 bar = 700 kPa
IP = 6.5 kW
 

 
5. A spray painting workshop uses a single stage, single acting reciprocating air compressor running at 240 rpm to
supply compressed air at a delivery pressure of 7.5 bar. The amount of air delivered when measured at ambient
conditions of 1.013 bar and 150C is 0.68 m3 per minute. The pressure and temperature at the end of suction stroke are
1 bar and 27oC. The clearance volume is 6 % of stroke volume. The compression and expansion process follows the
law PV1.28 = C.

Evaluate the following for the compressor:

(i) Volumetric efficiency;

(ii) Diameter (D) and stroke length (L) of the cylinder; (Take L = 1.1 x D)
(iii) Indicated power;
(iv) Isothermal work input and isothermal efficiency;

Given:  N = 240 rpm

Vf = 0.68 m3/min = 0.01133 m3/s L = 1.1 D,
Pf = 1.013 bar, Tf = 15oC = 288 K P2 = 7.5 bar, PV1.28=C
P1 = 1 bar =100 kPa, T1 = 27oC = 300K Vc = 6 % of Vs = 0.06Vs
= 0.06
 
 

==
6. Air enters a single stage, single acting reciprocating air at atmospheric conditions of 1 bar and 27oC. Compressed air
is delivered at a mass flow rate of 0.7 kg/min and 5.2 bar pressure. The clearance volume is 3.5% of stroke volume.
The compressor speed is maintained constant at 450 rpm. Assume that the compression and expansion follows the
law PV1.25 = C. Evaluate the following:

(i) Diameter (D) and stroke length (L) of the cylinder (Take L = 1.4 x D);
(ii) Volumetric Efficiency of the compressor.
(iii) Indicated power for the compressor in kW;
(iv) Brake power required to run the compressor if the mechanical efficiency of the compressor is measured as 82%;
Assume R = 0.287 kJ/kgK for air.

Given:
m = 0.7 kg/min = 0.01167 kg/s
P1 = 1 bar =100 kPa, T1 = 27oC = 300K
N = 450 rpm
L = 1.4 D
P2 = 5.2 bar =520 kPa, PV1.25=C
Vc = 3.5% of Vs = 0.035Vs
 
 
7. A single acting two stage air compressor with complete intercooling receives air
during suction at 1.2 bar pressure and 26ᵒ C temperature and thereby delivers air by
18 bar pressure with 11 kg/min. Take the polytropic index n as 1.3. The compressor is
running at 440 rpm and the clearance ratio of the low pressure (LP) and high
pressure (HP) cylinders are 0.03 and 0.05 respectively. Estimate the following

(i) The power required to drive the compressor;

(ii) The isothermal efficiency;
(iii) The free air delivered;
(iv) The heat transferred in intercooler;
(v) The volumetric efficiency of both LP and HP cylinders.

Given:
P1 = 1.2 bar =120 kPa, T1 = 26oC = 299K
P2 = 18 bar =1800 kPa
Amount of air delivered: m = 11 kg/min = 0.1833 kg/s
PV1.3=C
N = 440 rpm
Clearance ratio for low pressure compressor: KLP = 0.03;

Clearance ratio for low pressure compressor: KHP = 0.05

 (i)Power required: (Work done in two stages with perfect intercooling)
= 50.00 kW

(ii) Isothermal efficiency:

= = 4;
x100 = x100 = 85.2%;

(iii) Free air delivery (F.A.D):

=7.86
 (iv) Heat transferred in intercooler:
Intermediate pressure = = = 4.65 bar

Temperature at the end of compression

=> => = 408.72 K
Heat transferred in intercooler = = [ie.T5 = T1]
perfect intercooling = 20.21 kJ/sec

(v) Volumetric efficiency for L.P. stage,

= 0.9449 x100 = 94.49%

volumetric efficiency of H.P stage,

= 0.9083 x100 = 90.83%
Tutorial No.1
Determine the size of the cylinder of a double acting air compressor of 32kW, in which air is drawn in at 1bar and compressed
16bar according to the law PV1.25=C. Assume Speed of compressor = 300 rpm and piston speed is 180m/min. Take volumetric
efficiency of compressor as 80%

Tutorial No.2
A single stage double acting air compressor delivers air at 7 bar pressure. The amount of free air delivered is 2 m3 per minute at
300 rpm. The pressure and temperature at the end of suction stroke are 1bar and 27oC. The ambient conditions are 1.03bar and
20oC. The clearance is 5% of stroke. Assume Compression and re-expansion follow the law PV1.3=C
Determine
(i) Volumetric efficiency under ambient conditions;
(ii) Diameter and Stroke of the cylinder (Take D=L).

Tutorial No. 3
A single stage single acting air compressor delivers 15m3 of air per minute measured at 1.013bar and 27oC. The delivery pressure
is 7 bar. The conditions at the end of suction stroke and free air delivery are same. The clearance volume is 4% of swept volume
and stroke to bore ratio is 1.30:1. The compressor runs at 300rpm. Assume Compression and re-expansion follow the law
PV1.3=C
Calculate
(1) Volumetric efficiency;
(2) Indicated Power;
(3) Isothermal efficiency;
(4) Cylinder dimensions; and
(5) Adiabatic efficiency compressor.